To worcester



c. ALVORD' METHOD OF AND APPARATUS FOR MANUFACTURING TUFT YARN FRAMES Re. 18,903 2 Sheets-Sheet 1 Jul '25, 1933.

Origmal Filed Aug. 11, 1930 wwx INVENTOR A'ITORNEYS CgnT n Alvbrd C. ALVORD METHOD OF ANDAPPANATUS FOR MANUFACTURING TUFT YARN FRAMES Original Filed Aug. 11, 1930 2 Sheets-Sheet 2 July 25, 1933.

; i INVENTOR h: CgnTon -AVOTd I ATTORNEYS Reissued July 25, 1933 UNITED STATES PATENT .oF-Fieg CLINTON ALVOR-D, OF WORCESTER, MASSACHUSETTS, ASSIGNOR .TO WORCESTER LOOK WORKS, F WORCESTER, MASSACHUSETTS, A CORPORATION OF MASSACHUSETTS METHOD OF ANDVAPIVARA'ITUS FOR MANUFACTURING more YARNTRUAJTES I Original No. 1,851,798, dated March 29, 1932 ,'Ser ia1 No. 474,332,}fi1ed August 11, 1930. Application! 1 reissue med April 193s. Serial 170.6%,648. I v

' This invention relates to the manufacture F ig. Q/is a view in end elevation of one of Y of tuft yarn frames such as are employed in looms for weaving'tufted pilecarpets whereinthe'yarns are'either Withdrawn from the frames bygrippers or the frames themselves are successivelypresented at the pile form ing position.

Theobject of theinvention is to provide a method and apparatus by which the yarn guides in tuft frames of all widths maybe spaced with absolute accuracy and permanently secured as thus spaced in position on the frame.

A further object ofthe invention is to provide a method and apparatus for producing such tuft yarn, frames rapidly and economthreaded and in use.

icallyand at a minimum cost;

A- further object of the invention is to provide a method and apparatus for producing tuft yarn frames of that type in which the yarn guides are provided with joints and in WlllCll the oints are permanently secured to-,

geth er soas to prevent the opening or spreading apart of the'yolnts when the frames are These and other objects and features of the invention will appearmore fully from theaccompanying description and drawings and i will be claims. 7 7 V As the general purpose and function of a tuft yarn frame for use in a loom for weaving tufted pile carpets is Well known and fan'iiliarto those" skilled. in the art, andas various types of construction are adapted to be made by the method and apparatus of this invention it will'b-e suflicient here to illustrate and describe twotypes of such tuft yarn frames as typical. In the one type the yarn guides are formed as separate elements with overlapping joints and" these elements are individually secured to the carrier bar of the frame, while in the other type the yarn guides are formed in a unitary series in a particularly pointed out in the I crimp-ed strip of metal which'as an. entirety is secured to the carrier bar In the drawings: Fig. 1 is a diagrammatic elevation ofa simple form of apparatus employed in carrying out the method of the invention.

of the frame.-

and the unequal temperatures the time the solder sets.

thetwdpart separable holders with a tuft yarn frame of the first type in place therein.

Fig. 3 is aview similar to Fig; 20f another ,1 v

form of two-part separable holder with a tuft yarn frame of the second type inv place therein.

Fig. 4 is a frontelevation partially broken away showing a plurality of the two-part J separable holders with a complete tuft yarn frame of the first type in place'therein.

-Fig. 5 is a 'fragmentary perspective view 'of a spacer such as employed in the construction sliown in Figs. 2 and 4.

Fig. 6 is an enlarged endelevationvof a single yarn guide having overlappi join of the type shown in Figs. 2' and 4'.

Fig. 7 is a perspective view of aportion of the yarn guide'structure of the second type. i

trate between the warp yarns when the'frame is dipped to insert the pile and the result would be a. defect in the fabric or carpet be ing woven. These tuft yarn frames are often twelve or more feet in length and there is a very substantial number of yarn guides per This invention enables such frames of any type and ofany length to be formed inch depending upon the fineness of the weave.

with the yarn guides permanently andrigidly secured in position to the carrier. bar or main element of the frame and with all the yarn guides aceuratelyand equally'spaced.

.VVhile soldering methods for securing the yarn guides in place have long been-used,' it has beenpractically impossible to secure uniform and accurate results because ofthe dif-' guides and the gauges employed were ralsed One important feature of the'present in- 'ference in temperatures to which theyarnprevailing at v ven'tion resides in the employment of spacer means for positioning the yarn guides withrespect to the carrier bar of the frame and in the raising ofthe entire ensemble to a uniformtemperature sufiicient to melt the sol- .der andthen-the gradual lowering of the temperature of this entire ensemble to apoint Where the solder sets, thus ensuring that the spacing of the yarnwguidesis maintained throughout the entire operation and that there is no possibility of the yarn guides being'secured to the carrier bar otherwise than in the required accurate and equal spacing.

' Referringxparticularly to the construction illustrated inFigs. 2, 5, and 6, it will be" seen that the yarn g-uide frame comprises a'carrierbar 1 shown as a rigid, rectangular tube of metal, thus presenting great strength =and rigidi ty, and a series of yarn guide tubes 2.", Each ofthesefyarn guidesis of similar shape and is formed of sheet metal, usually tin plated,having overlappinglongitudinal back edges, as shown in Fig.;6,.where the backedge 3 overlaps the ba'ck edge The ends ofthese overlapped back edgesof the yarn guides overlie the carrier bar, as clearly shown in Fig. 2, and these'overlapping edges are secured together and the yarn guides are 1 secured to a ca-rrierbar by solder sothat,

.when the operation is completed, a, firm and rigidv unitarystructure prese nted.

Y In order: properly ,to-spac-e and position the yarn guides with respect to the carrier bar, there is provided, 111 accordancewith this invention, a temporaryyarn. guide spacer, a

section-ofwhich isshown in perspectivein .pendingziipon the length of the frame or carrier bar. preferred construction of such holder for .use in forming .atubular yarn 'spaced 'and assembled. Preferably also a plate 701? metalextends along thefront face of the block fiagainst which the front ends oftheyarn guides abut and are thus. posi-- tioiied longitudinally.

, .A plurality of two-part separable'holders is provided, the number ofthese holders de guide frame of thefirst type is shown in Figs.

' screws 11, as shown.

1 and 4. Each holder forms a two-part separable clamp, One part 8 of the holder or clamp presen'ts a flat base9'and'a flat seatlO,

upon which the temporary "spacer sand the plate-7 areseated; Thespacer 5 is also'se- .cured to the holder or clamp part Shy set WhenQallthe parts 8 of the'holders. or

' elanips'aresecured in position to the spacer and the plate 7 is'in place, the tubular yarn the projections?) withthe forward ends abutting the plate 7. A long retaining bar 12 is thenplaced on top of the entire series oftubular yarn guides and clamped down against theyarii guides by set screws 13,,one such set screw being vertically threaded in a lug 14 projecting laterally from each holder part 8.

The second part of each holder is somewhat U-shaped, .as shown at 15, and ofa size sufficient to receive the carrier bar 1. I One leg of this part of the holder 01' clamp fits in a suitable recess 16 of the lower holder part and is provided with a notch 17 engaged by aispring-pressed plunger 18 mounted in the lowerholderpart. The otherleg is also providedwith a notch 19 engaged bya similar spring-pressed plunger 20. A plunger 21 n ounte'd vertically in the uppeifliolde'r part is depressed by ajsprin g 22 into engagement with the carrier bar.

The parts to be soldered are treated with a suitable flux. This is particularly important in the case of that portion of the overlapped back edgesof the yarn guides projecting 'laterallyjfrom the carrier bar because" thelflux causes the solder appliediatthe end portions of the yarn guide to run substantially the full length of the yarn guides and .insures the soldering together. of substantially the entire length of the j oint formed by the 3 overlappedback edges. The flux may be con veniently applied'to the tubular yarnguides 2 after thetemporary" spacer 5, the plate 7 and'the yarn guides have been assembled in the lower holder part; 7

Asheet'or strip of solder-suchas'23 is next laid on the ends ofthe back-overlapping edges of the tubular yarn guides. Thecarrierhar 1 is then placed in the upper holder part 15 and this holder part is the iplaced in position on the lower holdeivpart andthe plu'ngers 18 and 20 snap into, positionandlock the holder parts or .cla mps'together. In this position the spring-pressed plungers 21 act. yieldingly'to press the row of positioned yarn guides and the carrier bar togetherwith the strip or layer ofsolder 23int erposed between the 1 ends of theoverlapped backedges of the yarn guides and theffront surface of the "carrier bar.- The left hand. holder 5 is provided at one endwith an upturned stop 24 to position thecarrier bar longitudinally with respect to the tubular yarn guides. An abutting post 25' on each lower: holder 5 extending up to a point-slightly below the level of the top ofthe positioned-yarn guides prevents the carrier bar from tipping while the parts are being assembled. When the assembly is completed, the spring-pressed plungers-21 hold the carrier bar in proper positionclear are readily assembled by. forcing theupper guides 2 are positioned the spaces betweenbevelled atv their free ends, to spring into the 1 ofth eseiposts 25. The holder or clamp parts notches 17 and 19, and the two holderior' clamp parts are quickly detachable by pressing the plungers 18 and 19 inward by means of the handles 26.

The ensemble comprising a plurality of the two-part holders or clamps, the tempo rary spacer 5, the plate 7, theseries of tububar and the positioned yarn guides together,

thus causing not only the yarn guides and the carrier bar but the overlapped back edges of the yarn guides all thoroughly to be soldered or sweated together. The temperature of the entire ensemble is then gradually reduced to room temperature or to the point where the solder is set, the yielding pressure of the plunger-s being maintained throughout. The operation is nowcomplete and the clamps or holders are removed, together with the temporary spacer. The result is a tuft yarn frame in which all the tubular yarn guides are accurately and equally spaced and permanently and thoroughly securedin position to the carrier bar, and the overlapped back edges of the yarn guides are soldered together substantially for their full length.

A preferred form of apparatus for raising and lowering the temperature of the ensemble is shown somewhat diagrammatically in Fig. 1. It comprises an oven 27 of sufficient length and size to contain the entire ensemble. This oven may be heated by gas or other suitable means and is preferably provided with thermostatic means for maintaining it at a constant temperature of, say, about 445 F. Doors 28 and 29 are provided at the ends of the oven. An assembly table 30 is located at one end of the oven anda cooling table 31 at the other end. These tables present righl, flat upper surfaces. The ensemble is preferably put together on the assembly table30. When completed, the door 28 is opened and the ensemble is pushed into the oven. It then remains'in the oven a sufficient length of time,

say about thirty minutes, to enable all the parts of the ensemble to reach a uniform temperature above the melting point of the solder. The door 29 of the oven is then opened and the ensemble drawn ou-t'upon the cooling table 31 and left until the ensemble reaches room temperature and tlresolder sets. The rigid flat surface of the cooling table 31 insures that the tube frames shall not become warped while cooling. When the ensembleis removed from the oven, the operative makes sure that the carrier bar is against the stop 24 and, if it is not, taps the carrier bar with a hammer to bring it into this position.

The process and apparatus employed in connection with the second type of tuft yarn frame is similar to that already described.

As illustrative of this type, there is shown in Fig. 7 in perspective a portion of tuft frame such as disclosed in the patent to Alvord, No. 1,713,506, granted May '14, 1929. The only difference in this case isthat the twopart separable holder orclamp is of a slightly different design to accommodate this type of tuft frame. One'of the holders or clamps for this purpose is shown in Fig. 3. In this case the carrier bar 32 is seated in the lower holder part 33 which is of general U shape. The strip 34 forming the series of yarn guides is placed in position overlying the carrier bar with the strip 35 of solder interposed. The temporary spacer 36 is shaped as shown in Fig.- 8 with the projections 37adapted to fit in the spaces forming the yarn guides of the strip 8%. This spacer is placed in position with a suitable end positioning plate 38. The upper holder part 39 is then placed in position and is provided with spring-pressed plungers 40 similar to those'already described by which the two parts of the holder are detachably connected. together. 7 The spring-' pressed plunger 41 in the upper holder member abuts the temporary spacer 86 and thus acts yieldingly to press the yarn guide strip and carrier bar with the interposed strip of solder together. A positioning lug 42 on the end of the temporary spacer-36 has the same function'as the lug 24: already described.

After the parts have been assembled, the entire ensemble is then treated in the same manner as already described. The result is that the yarn guide strip 34 is permanently and rigidly secured to the carrier bar with the spaces forming the yarn guides all ac curately and equally positioneth There is thus presented asimple form of apparatus and method by means of which tuft yarn frames may be easily and economically manufactured and in which the yarn guides will be accurately and equally spaced throughout and rigidly and permanently se cured in position.

Having thus described the invention, what is claimed as-new, and desired to be secured by Letters Patent, is:

1. The process of forming a tuft yarn frame which comprises assembling a carrier bar, a plurality of yarn guides, and a temporary yarn gulde spacer with the spacer accurately and uniformly positioning the yarn guides, with the ends of the backs of the positioned yarn guides overlying the carrier,

bar, and with a layer of solder interposed between the said yarn guides and the carrier bar, raising the temperature of the ensemble to a point sufficient to melt the. solder, thereafter gradually cooling the ensemble to room temperature,maintaining a yielding pressure acting to force the yarn guides and carrier bar together while the temperature of the ensemble is beingraised and while it is being lowered to a point wherethe solder is set, and

removing the temporary spacer.

2. The process of forming a tuft yarn frame comprising the steps defined in claim 1, together with supporting the ensemble during the cooling step straight upon a rigid support.

i 3. The proc'ess of forming a-tuft yarn frame which comprisesassembling a carrier bar-,a plurality of yarn guides, and atemporary yarnguide spacer with the spacer accurately and uniformly positioning the yarn guides, with the ends of the backs of .the positioned yarn guides overlyingthe' carrier bar, and with a layer of solder -inter-' posed between the said yarn guides and the i carrier bar, placing the ensemble in an oven maintained at a temperature above the melting point of the solder, leaving the ensemble:

in the oven until it has reached the said temperature, thereafter gradually cooling'the ensemble to room temperature, maintaining a yielding pressure acting to force the yarn guides and carrier bar together while the temperature oft-he ensemble is being raised and while it is being lowered to a pointwhere the solder is set, and removing the temporary spacer.

4. The process of forming a tuft yarn frame comprising the steps defined in claim .3, together with supporting the ensemble during the cooling step straight upon a rigid support.

5. The process of forming a tuft yarn frame which comprises assembling a carrier bar, a plurality of tubular yarn guides each having overlapping-Iongitudinal backedges, and a temporary yarn guide spacer with the spacer accurately and uniformly posit oning the yarn guides, withthe ends of the overlapped backedges of the positioned yarn guides overlying the carrier bar, and with a layer of solder interposed between the yarn guides and the carrier bar, raising the temperature of the ensembleto a'point suflicient to melt the solder, thereafter gradually cool-. ing the ensemble to room temperature, maintaining a yielding pressure acting to force the overlapping back edges of the .yarn guides together and the yarn guides and carrier bar togetherwhile the temperature of the ensemble is being raised and while it is being lowered to a point where the solder is set, thus to effect a permanent union both between the overlapped edges of the yarn guides and between the yarn guides and the carrier bar and removing the temporary spacer. a I

6. The'process of forming a tuft yarn 5, together with 'supportingthe ensemble during the cooling step straight upon a rigid su port. 1

' The process of forming a tuft yarn frame comprising the steps defined in claim '5, together with applying a flux to the overlapped ba'ck edges of the yarn guides whereby the solder interposed between theends of the yarn: guides and the carrier bar fiows frame comprising the steps defined in'claini throughout substantially the length of the yarn guides andzefi'ects a'permanent union betweenthe overlapped edges of the yarn guides substantially throughout their length.

8. The process of forming a tuft-yarn framewhich comprisesassembling a carrier bar, a plurality of tubular yarn guides each having overlapping longitudinal back edges, and a temporaryyarnguide spacer with the spacer accuratelyand uniformly positioning the yarn guides, with the ends of the overlapped back edges of the, positioned yarn guides overlying the carrier bar, and with a layer of solder interposed between the said yarn-guides and the carrier bar, placing the ensemble in an oven maintained at a tem- Y perature above the melting point of the. solder, leaving the ensemble in the oven untilit has reached the said temperature, thereafter gradually cooling the ensemble to room temperature, maintaining a yielding pressure acting to force the overlapping back edges of the yarn-guides together'andthe, yarn guides and carrier bar together while the temperature of the ensemble is being raised and while it is being lowered to a point where the solder is set, thus to effect a permanent union both between theoverlapped edges of the yarn guides and between theyarn guides and the carrier bar and removing the temporary spacer. I

9. Thejprocess of forming a tuft yarn Y frame comprising the steps defined in claim 8, together with supporting the ensemble during the cooling port.

10. The process of forming a tuft yarn frame comprising the steps defined in claim 8, together with applying a flux'to the over lapped back edges of the yarn guides whereby the solder interposed between the ends of the yarn guides and the carrier bar flows throughout substantially the length 0f the yarn guides and effects a permanent union between the overlappededges of they'arn guides substantially throughout their length. i *11. An apparatus for forming a tuft-yarn frame comprising atwo-part separable holder, a yarn guide spacer mounted in one holder part to: position accurately and uniformly tuft frame-yarn guides in parallelism and in straight alignment, means in the other holder part to support removabl-y a carrier bar with its front surface/ in juxtaposition to the ends of the backs of the positioned yarn guides and step straight upon a rigid supmeans on one holder part acting yieldingly to press the row of positioned yarn guides and carrier bar together when the holder parts are assembled.

' claim 11, together with cooperating, springactuated, locking means on the holder parts for locking them together in assembled position. Y

14. An apparatus for forming a tuft yarn frame comprising a series of similar twopart, separable, transversely spaced clamps, a long rigid spacer extending transversely of and mounted in one part of each clamp to position accurately and uniformly tuft frame yarn guides in parallelism and in straight alignment, aligned means in the other part of each clamp to support removably'a carrier bar with its front surface in juxtaposition to theends of the backs of'the positioned yarn guides, and means on each clamp acting yieldingly to press the row of,

positioned yarn guides and carrier bar together when the apparatus is assembled with the yarn guides and carrier bar therein.

15. The process of forming atuft yarn frame which comprises assembling a carrier bar, a plurality of yarn guides, and a temporary yarn guide spacer with the spacer accurately and uniformly positioning the yarn guides, with the ends of the backs of the positioned yarn guides overlying the carrier bar, andwith a strip of solder positioned in proximity to the said. yarn guides and the carrier bar, raising the temperature of the ensemble to a point sufiicient to melt the solder, thereafter lowering the temperature of the ensemble to a point where the solder is set, and removing the temporary spacer.

16. The process of forming a tuft yarn frame compr1s ng the steps defined in claim 15, together with supporting the ensemble n'oximit 7 to the arn uides and the carrier bar, raising the temperature of the ensemble .to a point suflicient to meltv the solder, thereafter lowering the temperature of the ensemble to a point where the solder is set to effect a permanent union both between CLINTON ALVORD. 

